Apparatus for and method of making precast concrete piling



Jan. 21, 1930. F. T. LEEDER 1,744,702

APPARATUS FOR AND METHOD OF MAKING PRECAST CONCRETE FILING Filed Nov.10, 1928 2 Sheets-Shee 1 glwuento'a Jan. 21, 1930. F. T. LEEDER1,744,702

APPARATUS FOR AND METHOD OF MAKING PRECAST CONCRETE FILING Filed Nbv.10, 1928 2 Sheets-Sheet 2 m Za/wa fieder Patented Jan. 21 1930 FRANCIST. LEEDER, OF SIOUX CITY, IOWA APPARATUS FOR AND METHOD OF MAKINGPRECAST CONCRETE PILING "Application filed November 10, 1928. Serial No.318,395.

My invention relates to the art of pre-casting concrete piling and hasfor its primary object to provide a method and apparatus, by means ofwhich a large number of piling can be made in a small space.

The problem of casting concrete piling in places where space isrestricted is a serious problem, for the reason that each pile must beallowed to cure for a period of time ranging from eight to fifteen daysbefore it is in condition to be driven.

Consequently in a job where a large number of piling is required, it isnecessary to cast anywhere from two to three times as many piling as canbe driven in a single daybefore the driving operation commences sothatthere may be a full supply of cured piling ready for each day's drivingand enough piling in various stages of curing to provide for thesucceeding days of driving.

As it is possible ordinarily to drive at least twenty-five piles a day,it will be seen that the minimum number of piling which would benecessary in any job of any size to have in readiness at. any one timewould be two hundred.

My invention aims to provide a method of casting piling whereby theindividual piles may be grouped side by side with face to face contactand in tiers one on top of the other during the curing process.

My process, therefore, contemplates the employment of a preliminary setof piling as forms for a second seat.

A further object is to provide an apparatus which may be withdrawnreadily from a preliminary set of spaced piles without disturbing thespaced relation of said piles.

A further object is to provide an apparatus including means foraccurately spacing the forms, said means also serving to close the endsof the forms.

With these and other objects in View, my invention consists in theconstruction, arrangement and combination of the various parts of mydevice, whereby the objects contemplated are attained, as hereinaftermore fully set forth, pointed out in my claims, and illustrated in theaccompanying drawings, in

which Fig. 1 a plan view of a set of piling constructed according to myinvention;

gig. 2 is a sectional .view showing the butt on Fig. 3 is a plan view ofa portion of the forms partially set up.

Fig. 4 is an inner side elevation of the butt end cap of the apparatus.

Fig. 5 is a sectional View through the same attached to the forms.

Fig. 6 is an inner side elevation of the nose end cap of the apparatus.

Fig. 7 is a sectionalview of the same attached to the forms.

Fig. 8 is a transverse, sectional view through the forms set up for thefirst pouring operation.

Fig. 9 is a similar view showing the first pouring operation completed.

Fig. 10 is a similar view after the forms have been removed and thesecond pouring operation has been completed.

Fig. 11 illustrates the operation similar to that shown in Fig. 9 on thesecond tier of piling.

Fig. 12 is a perspective view of a piling, cast according to my method.

Fig. 13 is a sectional View showing the nose end cap used for forming apile of the second series.

The amount of space required for casting about forty-eight piles,according to my method, will be a space equal to the length of thepiling multiplied by the width of sixteen piles. For an eighteen inch bythirty foot pile, this will be approximately twenty-four by thirty feet.

The surface upon which the piling is to be made is first prepared bysmoothing the earth to a perfectly smooth finish and as nearly level aspossible. It will be understood that ordinarily the piling will be castout in the open in a vacant lot or some portion of the yard adjacent thebuilding operations.

After levelling the earth, which is indicated in Figs. 8-'11, inclusive,by the reference character 15, a sheet 16 is spread over the entiresurface so as to cover all of the earth. This sheet may be made ofseveral strips of red resin paper or the like and is for the group ofpurpose of giving a smooth surface to the lower sides of the piling andto prevent earth from adhering thereto.

The forms are shown innFig. 3 and comprise primarily the planks 17,which are adapted to be positioned vertically, resting on their edges.As will be noted in Fig. 8, the forms 17 are positioned in pairs,adapted to be secured together so that the outer faces of each pair offorms are spaced from the outer faces of the adjacent pair of forms oneither'side thereof a distance equal exactly to the width of a pile.

Furthermore, the distance between the outer face of any one particularair of forms is also exactly equal to the width of a pile whereby afterthe forms have been removed to leave a first series of piling, thedistance between the side faces of said first series will be just theright amount to provide forms for a second series of piling. In order tospace the pairs of forms from each other, I provide the end caps, shownin Figs. 47 inclusive. The butt end cap, shown in Fig. 4, comprises aninner plate 18, provided with a bevelled rim 19, terminating in theflange 20, which is perpendicular to the plate 18. The flange20 iscontinued to form a flange 21,

parallel to the plate 18. The flanges 21 are located on two sides onlyof the plate and are adapted toabut against the ends of the forms 17,the flanges 20 being received between the inner faces of the forms andserving to space the forms the exactly correct distance apart.

The purpose of the bevelled rim 19 is to form bevelled corners 19 at thebutt ends of a pile, and in driving the pile, a driving cap' 19 isemployed, which fits the contour of the butt end of the pile. Drivingpressure against the driving cap is transmitted to the pile as indicatedby the arrows in Fig. 14, preventing spalting or chipping of the cornersof the pile during the driving process.

The nose end cap shown in Fig. 6 comprises a pyramidal cup 22, two sidesof which teminate in flanges 23, positioned in a common plane so as toabut against the ends of the forms 17.

In order to space the forms of an individual pair from each other, Iprovide spacing blocks 24, adapted to be nailed to vertical cleats 25,permanently secured to the forms 17. The blocks 24 are exactly theproper length to space the forms apart. WVhere the forms are set up toproduce tapered piling, as shown in the drawings, the blocks 24 aresuccessively reduced in length and properly identified so that eachblock may be placed in its correct position.

In setting up the forms, each pair of forms may be arranged in properlyspaced relation and the various pairs spaced by means of the end caps.The end caps are preferably secured in a temporary fashion by nailingthrough the flanges 23 and 21, respectively, into the ends of the formsand after the forms have been adjusted so that the ends of all of theforms are aligned in the proper arcs of circles, stakes 26 are driveninto the earth in line with the forms 17 and against the flanges 23,while the butt caps are held in place by a plank 27, curved to engagethe series of caps and held securely in place by stakes 28, driven inthe ground.

The forms now being securely positioned, they are ready for the .pouringoperation. Prior to the securing of the end caps in place, however, thereinforcing element shown at 29 in Fig. 3 is placed in position. Thereinforcing element employed in producing piling, according to myinvention, comprises four corner longitudinal rods 30 (Fig. 9) and asquare coil 31, secured to the rods 30 by means of wire loops 30*. Thecoil is pyramidal in shape, and the rods are thus positioned inconverging relation to each other in the finished reinforcing element.Thus a reinforcing element is produced which conforms to the shape ofthe pile, and is imbedded at all points to the same depth in the sidesof the pile. Such an element is much easier to make than one, forinstance, which is formed of longitudinal rods and individual connectingloops.

Concrete is now poured between each pair of forms as illustrated in Fig.9, thus forming a first series of piling, each pile being spaced fromits neighbor by a space equivalent to the dimensions required of anotherile. p During the puddling of the concrete, the reinforcing element islifted by means of a crow bar with a hooked end, or the like, and

thus brought to its position properly centered in the form. As theconcrete flows under the element, it serves to support it in thatposition.

'The next step in the process is to remove the forms. In order to removethe forms without disturbing the relation of the piling, they must bemoved inwardly toward each other and this may be accomplished in asimple manner by removing the blocks 24, whereupon the forms maycollapse inwardly as indicated in Fig. 3 and be lifted upwardly frombetween the piling.

The piling is, of course, allowed to set before removal of the forms andafter the forms have been removed, is allowed to dry for ten totwenty-four hours before the next series is poured.

I have indicated the first series of piling by the reference character32.

After the first series of piling has dried for 10 to 24 hours, thesecond series is poured, as illustrated in Fig. 10, wherein the secondseries is referred to by the reference character 33. Before pouring'thesecond series, the sides of the first series are covered with a layer ofheavy black oil, grease or paraffin oil. This coating, indicated by thereference character A, prevents adhesion between the vertical faces ofthe piling.

In preparation for pouring the second series, the butt caps are securedin place by driving stakes against their flanges to secure the flangesagainst the ends of the first series of piling. The butt caps aresecured between the piling in the same way as they were originallysecured between the forms 17, with the exception that they are notnailed in place. The nose caps used for the second series are shown,at22 in Fig. 13 and differ from the caps 22 in that their flanges 23* arebent at right angles to their sides. Stakes 34 are used to secure themin place.

After the second series has been cast, it is allowed to set and the endcaps removed. After ten to twenty-four hours drying, a sheet 35, redresin paper, similar to the sheet 16, is laid over the upper surface ofthe piling and the forms are then built upon this second sheet in thesame manner as for the first series of piling.

The third series of piling is indicated by the reference character 36and is cast and allowed to dry in the same manner as the first series.After removal of the forms and drying of the third series, a fourthseries is cast between the third series and allowed to set and to dry.Another sheet similar to the sheet 16 is then laid over the second tierof piling and a fifth and sixth series cast in the same manner as thepreceding series.

In some cases, it may be necessary to cast four tiers of piling,although I find that the difiiculties of removing the upper tier arequite enhanced, as compared with removing the third tier.

In removing the piling, it is necessary to move the outer pile of theupper tier by means of a crowbar or the like until a hook can beinserted behind the pile. A team of horses or a tractor is then hitchedto the pile and it is pulled away from the supporting pile beneath andallowed to drop to the ground. The pile may be then snagged to theposition where it is to be driven.

In Fig. 2, I have used the reference char acters 37, 38 and 39,respectively, to indicate the fourth, fifth, and sixth series of piles.

The advantage of the casting of a large number of piling in a smallspace is accom-,,

perfect supporting surface for a second tier of piling. By utilizing theseparating sheet, the second tier may be poured without danger ofadhering to the first tier. When the several tiers have been completed,there is a solid mass of piling filling all of the space above thesurface on which the piling is cast to a depth of several feet andeasily separable into individual piles.

The present process eliminates fifty per cent of the cost of forms andform setting. It also eliminates casting platforms.

The cost of the operations on the second or third tiers ofpiling is lessthan that of the first due to the elimination of the necessity forpreparation of the bed or supporting surface, in the latter steps. Abovethe third layer, the expense is somewhat increased due to increasedlabor cost in transporting the concrete to the higher levels.

Some changes may be made in the construction and arrangement of theparts of my invention without departing from the real spirit and purposeof my invention, and it is my intention to cover by my claims, anymodified forms of structure or use of mechanical equivalents, which maybe reasonably included within their scope.

I claim as my invention:

1. The method of making concrete piling of the type that is square incross section, comprising the following steps: providing a smooth, fiatsurface; covering said sheet;

building forms upon said sheet, which, when filled with concrete, form afirst series of piling, each of which is separated from its neighbor bya space which has the exact dimensions of a pile; allowing said firstseries to partially cure; utilizing said first series as forms for asecond series by filling said spaces with concrete; allowing said secondseries to partially cure; all of said first and second series beingdisposed in horizontal positions with one side face of each pile formedagainst the bottom sheet; covering the upper faces of the first andsecond series with a second sheet; and repeating the aforesaid stepsupon the second sheet.

2. The method of making concrete piling of the type that is square incross section, comprising the following steps: providing a smooth, flatsurface, covering said surface with a bottom sheet; building forms uponsaid sheet which, when filled with concrete, form a first series ofpiling, each of which is separated from its neighbor by a space whichhas the exact dimensions of a pile; allowing said first series topartially cure; utilizing said first series as forms for a second seriesby filling said space with concrete; allowing said second series topartially cure; all of said first and second series being disposed inhorizontal positions with one side face of each pile formed against thebottom sheet.

8. An apparatus for forming concrete piling of the type that is squarein cross section,

comprising: a plurality of pairs of elongated flat forms; each formhaving projecting elements on its side adjacent to its partner form;spacing blocks adapted to be secured to or removed from, said projectingelements fiat forms; each form having projecting elements on its sideadjacent to its partner form; spacing blocks adapted to be secured to orremoved from said projecting elements without disturbing the positionsof the forms; and means adapted to close the spaces between adjacentforms of adjacent pairs of forms, and to support the pairs in properlyspaced relation.

5. An apparatus for forming concrete piling of the type that is squarein cross section. comprising: a plurality of pairs of elongated fiatforms; spacing blocks adapted to be secured to or removed from saidforms without disturbing the positions thereof; and end caps adapted tobe secured between adjacent forms of adjacent pairs of forms to closethe spaces therebetween and to maintain the pairs in properly spacedrelation.

6. An apparatus for forming concrete piling of the type that is squarein cross section, comprising: a plurality of pairs of elongated fiatforms; spacing blocks adapted to be secured to or removed from saidforms without disturbing the positions thereof; and meansadapted toclose the spaces between adjacent forms of adjacent pairs of forms, andto support the pairs in properly spaced relation.

7. The method of making concrete piling of the type that is square incross section, comprising the following, steps: providing a smooth, flatsurface; covering said surface with a bottom sheet; building forms uponsaid sheet which, when filled with concrete, form a first series ofpiling, each of which is separated from its neighbor by a space whichhas the exact dimensions of a pile; allowing said first series topartially cure; oiling the vertical side faces of said first series ofpiling; utilizing said first series as forms for a second series byfilling said spaces with concrete; allowing said second series topartially cure;

' all of said first and second series being disposed in horizontalpositions with one side face of each pile formed against the bottomsheet; covering the upper faces of the first and second series with asecond sheet; and repeating the aforesaid steps upon the second sheet.

8. The method of making concrete piling of the type that is square incross section, comprising the following steps: providing a smooth, flatsurface, covering said surface with a bottom sheet; building forms uponsaid sheet which, when filled with concrete, form a first series ofpiling, each of which is separated from its neighbor by a space whichhas the exact dimensions of a pile; allowing said first series topartially cure; oiling the vertical side faces of said first series ofpiling;

utilizing said first series as forms for a second series by filling saidspaces with concrete; allowing said second series to partially cure; allof said first and second series being disposed in horizontal positionswith one side face of each pile formed against the bottom sheet.

9. The method of making concrete piling of the type that is square incross section, comprising the following steps: providing a smooth, flatsurface, covering said surface with a bottom sheet; building forms uponsaid sheet which, when filled with concrete, form a first series ofpiling, each of which is separated from its neighbor by a space whichhas the exact dimensions of a pile; allowing said first series topartially cure; providing means against the side faces of said firstseries of piling,'to prevent adhesion of a second series to said firstseries; utilizing said first series as forms for a second series byfilling said spaces with concrete; allowing said second series topartially cure; all of said first and second series being disposed inhorizontal positions with one side face of each pile formed againstthe'bottom sheet.

Signed this 8th day of November, 1928, in the county of Woodbury andState of Iowa.

FRANCIS T. LEEDER.

